Applications of THI®S-1001 (Butyraldehyde–Aniline Condensate) in Rubber Lining

THI®S-1001 is a high-performance liquid accelerator, with the chemical name Butyraldehyde-Aniline Condensate. Internationally, this compound is often abbreviated as BBA or BAA, both referring to the same type of product formed by the condensation reaction of butyraldehyde and aniline.

As an important member of the aldehyde-amine condensate accelerator family, THI®S-1001 possesses high reactivity, excellent thermal stability, and outstanding dispersibility. It is widely used in rubber processing and corrosion-resistant materials, demonstrating exceptional performance particularly in rubber lining systems.

1. Industry Background of Rubber Lining

Rubber lining is a commonly used composite material for corrosion protection, primarily used for the internal protection of equipment in chemical, environmental protection, metallurgical, and other industries. Typical application equipment includes storage tanks, reactors, desulfurization towers, pickling tanks, and wastewater treatment tanks.

Its core function is to isolate acids, alkalis, salts, and organic media from direct contact with the substrate by applying a rubber layer onto the surface of metal or concrete substrates, thereby extending equipment service life and enhancing operational safety.

Common rubber materials used for linings mainly include Chloroprene Rubber (CR), Chlorosulfonated Polyethylene (CSM), Ethylene Propylene Diene Monomer (EPDM), and Butyl Rubber (IIR). These rubber systems require efficient and stable accelerator combinations to ensure uniform vulcanization and rubber-to-substrate adhesion. THI®S-1001 (Butyraldehyde-Aniline Condensate) is one of the mainstream liquid accelerators widely used in such scenarios.

2. Chemical Characteristics and Mechanism of THI®S-1001

The primary component of THI®S-1001 is the condensation product of butyraldehyde and aniline (Butyraldehyde–Aniline Condensate).
It is a viscous, brownish-yellow liquid accelerator that exhibits the following key features in rubber systems:

• High vulcanization activity and stable reaction
THI®S-1001 effectively promotes vulcanization at relatively low temperatures and maintains excellent thermal stability, making it suitable for thick products and long curing cycles.

• Improved crosslink uniformity
In thick or large-sized linings, THI®S-1001 prevents under-curing and enhances crosslink density, resulting in denser structures and superior mechanical properties.

• Enhanced adhesion
The accelerator strengthens the chemical bonding between the rubber layer and the metal substrate, improving adhesion and aging resistance.

• Excellent compatibility in formulations
THI®S-1001 can be used in combination with other accelerators such as TMTD, MBTS, and CBS, allowing flexible adjustment of cure rate and scorch time while improving compound processability.

3. Typical Applications in Rubber Lining Compounds

In the production of corrosion-resistant rubber linings, THI®S-1001 (Butyraldehyde-Aniline Condensate) is often used as a primary or secondary accelerator in CR, CSM, and EPDM systems. Typical application scenarios are as follows:

CR-based Corrosion-resistant Lining Compounds: Added at 0.5–1.0 parts per hundred parts of rubber (phr), THI®S-1001 can significantly improve vulcanization uniformity and reduce the risk of undercure in the inner layers of the lining. It also enhances the adhesion between the rubber and the metal substrate, optimizing the lining's resistance to acids and alkalis and its peel strength.

EPDM Desulfurization Tower Linings: In EPDM systems, used in combination with 0.3–0.8 phr of THI®S-1001 and CBS-type accelerators, it can optimize the vulcanization curve, ensuring the lining maintains excellent elasticity and mechanical stability in the high-temperature and high-humidity environment of desulfurization towers.

CSM Chemical Storage Tank Linings: The heat resistance and controlled vulcanization release characteristics of THI®S-1001 make it suitable for CSM applications in high-temperature corrosive environments. The final vulcanized product exhibits a uniform structure and a dense surface, with corrosion resistance significantly superior to systems using conventional accelerators.

4. Application Advantages and Economic Value

Improves Vulcanization Quality of Thick Products: Enhances cross-linking uniformity, reducing defects such as internal bubbles and delamination in the lining, directly increasing product yield and reducing rework costs.

Extends Lining Service Life: Strengthens the bond between the rubber and metal substrate, improves the aging resistance of the lining in acid, alkali, and solvent environments, reduces the frequency of equipment lining replacement, and lowers long-term maintenance costs.

Reduces Overall Production Costs: As a liquid accelerator, THI®S-1001 has better dispersibility than solid accelerators, reducing mixing time. Furthermore, low dosage levels can achieve efficient vulcanization, potentially lowering the total accelerator addition cost and improving production efficiency.

Broad Compatibility with Rubber Systems: Can be adapted to mainstream corrosion-resistant rubber systems like CR, CSM, EPDM, and IIR, supporting diverse formulation design and process optimization, and reducing the need to stock multiple types of accelerators for different lining products.

5. Conclusion

THI®S-1001 (Butyraldehyde-Aniline Condensate) is a technologically mature and widely used liquid accelerator.

Thanks to its high reactivity, excellent thermal stability, and outstanding compatibility with various rubber systems, it has become a core additive in the corrosion-resistant rubber lining industry. It not only effectively improves vulcanization uniformity and enhances interfacial adhesion but also extends lining service life, providing an efficient, economical, and reliable solution for equipment corrosion protection in chemical, environmental protection, metallurgical, and other fields.

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